A noble metal-coated silver bonding wire for ball bonding wire includes a noble metal coating layer on a core material made of pure silver or a silver alloy, wherein the wire contains at least one sulfur group element, the noble metal coating layer includes at least one palladium layer, the total palladium content relative to the entire wire is not less than 0.01 mass % and not more than 5.0 mass %, and the total sulfur group element content relative to the entire wire is not less than 0.1 mass ppm and not more than 100 mass ppm.
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1. A noble metal-coated silver wire for ball bonding comprising a noble metal coating layer on a core material made of pure silver or a silver alloy,
wherein the wire contains at least one sulfur group element,
the noble metal coating layer comprises at least one palladium layer,
a total palladium content relative to an entire wire is not less than 0.01 mass % and not more than 5.0 mass %, and
a total sulfur group element content relative to the entire wire is not less than 0.1 mass ppm and not more than 100 mass ppm.
6. A semiconductor device comprising at least one semiconductor chip and a lead frame or a substrate, in which an electrode of the semiconductor chip and an electrode of the lead frame, the electrode of the semiconductor chip and an electrode of the substrate, or electrodes of multiple semiconductor chips are connected by a noble metal-coated silver wire for ball bonding,
wherein the noble metal-coated silver wire for ball bonding comprises a noble metal coating layer on a core material made of pure silver or a silver alloy,
the wire contains at least one sulfur group element,
the noble metal coating layer comprises at least one palladium layer,
a total palladium content relative to an entire wire is not less than 0.01 mass % and not more than 5.0 mass %, and
a total sulfur group element content relative to the entire wire is not less than 0.1 mass ppm and not more than 100 mass ppm.
2. The noble metal-coated silver wire for ball bonding according to
3. The noble metal-coated silver wire for ball bonding according to
4. The noble metal-coated silver wire for ball bonding according to
5. The noble metal-coated silver wire for ball bonding according to
7. The semiconductor device according to
8. The semiconductor device according to
9. The semiconductor device according to
10. The semiconductor device according to
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The present application is National Phase of International Application No. PCT/JP2018/016201 filed Apr. 19, 2018, and claims priority from Japanese Application No. 2018-070813, filed Apr. 2, 2018, the disclosure of which is hereby incorporated by reference herein in its entirety.
The present invention relates to a noble metal-coated silver wire for ball bonding suitable for a semiconductor device in which electrodes of a semiconductor chip and electrodes of lead frames or the like are connected by a bonding wire, and a method for producing the same, as well as a semiconductor device using the wire and a method for producing the same.
Conventionally, gold wires, copper wires, coated copper wires, and silver wires have been used as ball bonding wires for connecting electrodes of a semiconductor chip and external leads or the like in semiconductor devices. In the ball bonding wire, one end of the wire is melted by electric discharge, becomes spherical due to surface tension, and is solidified. The solidified ball is called a free air ball (FAB) and is connected to an electrode of a semiconductor chip by an ultrasonic thermocompression bonding method. The other end of the wire is connected to an electrode of a printed circuit board, a lead frame, or the like. Then, the connected bonding wires are resin-sealed to form a semiconductor device.
Gold wires, which are conventional bonding wires, have a high material cost, and copper wires and coated copper wires have a problem that their hard materials damage semiconductor chips. Silver wires are inexpensive and soft and are thus suitable as bonding wires. However, pure silver wires had a problem that their surfaces were sulfurized when they were left in the air for a long period of time, and silver alloy wires had a problem that electric resistivity increased when pure silver was alloyed with palladium or gold.
Accordingly, in order to solve the above problems, a coated silver bonding wire obtained by coating the surface of a silver wire with a platinum group metal such as palladium was proposed. The coated silver bonding wire solved the problem of sulfurization of the surface of the bonding wire; however, this wire was not satisfactory in terms of bonding reliability compared with gold wires for use in a severe environment of high temperature and high humidity in automobiles and the like.
For example, JP2013-033811A (Patent Document 1, described later) has proposed a palladium-coated silver bonding wire. The micrographs of FIGS. 4 (a) and (b) of this document show spherical balls having no unmelted portion of a palladium layer on the FAB surface. Claim 1 of this document describes “a bonding wire (W) for connecting an electrode (a) of a semiconductor element and a conductor wire (c) of a circuit wiring board by a ball bonding method, wherein a coating layer (2) of Pt or Pd is formed on the outer peripheral surface of a core material (1) made of Ag, and the ratio of the cross-sectional area (At) of the coating layer (2) and the cross-sectional area (A) of the wire (W) (At/A×100) is 0.1 to 0.6%.”
Further, paragraph [0021] of this document indicates that “in the production of FAB, when the wire tip is melted by electric discharge between the wire tip and the discharge rod g, Au, Pt, or Pd, all of which have higher melting points than Ag, is accumulated on the FAB surface; thus, the surface of FAB (ball b) becomes a high-concentration layer of Au, Pt, or Pd, and contributes to an increase in reliability at the bonding interface with the electrode a during the subsequent first bonding in FIG. 2 (b).” However, since the coating layer of Pt or Pd was melted into FAB, even if Au, Pt, or Pd added to the core material was accumulated on the FAB surface to form a high-concentration layer, the high-concentration layer did not secure long-term reliability at the bonding interface at a high temperature and a high humidity.
Accordingly, JP2016-115875A (Patent Document 2, described later) has been proposed. Claim 4 of this document discloses “a bonding wire for a semiconductor device, comprising an Au-containing region containing 15 to 50 at. % Au and provided on an outermost surface of the coating layer, wherein a thickness of the Au-containing region is 0.001 to 0.050 μm” . . . (omitted) . . . “comprising a core material containing one or more of Ga, In, and Sn for a total of 0.1 to 3.0 at % and a balance being made up of Ag and incidental impurities, and a coating layer formed over a surface of the core material containing one or more of Pd and Pt, or Ag and one or more of Pd and Pt, and a balance being made up of incidental impurities; wherein the coating layer is 0.005 to 0.070 μm in thickness.” However, when Ga, In, and Sn were added to the core material, there was a problem that the electric resistivity of the bonding wire itself increased, and this wire was not satisfactory as a palladium-coated silver bonding wire.
In a semiconductor device in which electrodes of a semiconductor chip and electrodes of lead frames or the like are connected by a bonding wire, when a noble metal-coated silver wire for ball bonding and an aluminum pad, which is the electrode of the semiconductor chip, are ball-bonded, corrosive intermetallic compounds of silver and aluminum are formed at the bonding interface. Since the intermetallic compounds easily corrode, corrosion penetrates into the bonding interface with time, and finally, a corrosion layer is formed between the aluminum pad and the bonding wire, thereby causing energization failure. Accordingly, an object of the present invention is to provide a noble metal-coated silver bonding wire that suppresses corrosion at the bonding interface and does not cause energization failure even under severe conditions of high temperature and high humidity in automobiles and the like.
The noble metal-coated silver wire for ball bonding according to the present invention is a noble metal-coated silver wire comprising a noble metal coating layer on a core material made of pure silver or a silver alloy, wherein the wire contains at least one sulfur group element, the noble metal coating layer comprises at least one palladium layer, the total palladium content relative to the entire wire is 0.01 mass % or more and 5.0 mass % or less, and the total sulfur group element content relative to the entire wire is 0.1 mass ppm or more and 100 mass ppm or less.
The method for producing a noble metal-coated silver wire for ball bonding according to the present invention is a method for producing a noble metal-coated silver wire comprising a noble metal coating layer on a core material made of pure silver or a silver alloy, wherein the wire contains at least one sulfur group element, the noble metal coating layer comprises at least one palladium layer, the total palladium content relative to the entire wire is 0.01 mass % or more and 5.0 mass % or less, and the total sulfur group element content relative to the entire wire is 0.1 mass ppm or more and 100 mass ppm or less.
The semiconductor device using a noble metal-coated silver wire for ball bonding according to the present invention is a semiconductor device in which an electrode of a semiconductor chip and an electrode of a lead frame, the electrode of the semiconductor chip and an electrode of a substrate, or electrodes of multiple semiconductor chips are connected by a noble metal-coated silver wire for ball bonding, wherein the noble metal-coated silver wire for ball bonding comprises a noble metal coating layer on a core material made of pure silver or a silver alloy, the wire contains at least one sulfur group element, the noble metal coating layer comprises at least one palladium layer, the total palladium content relative to the entire wire is 0.01 mass % or more and 5.0 mass % or less, and the total sulfur group element content relative to the entire wire is 0.1 mass ppm or more and 100 mass ppm or less.
The method for producing a semiconductor device using a noble metal-coated silver wire for ball bonding according to the present invention is a method for producing a semiconductor device, in which an electrode of a semiconductor chip and an electrode of a lead frame, the electrode of the semiconductor chip and an electrode of a substrate, or electrodes of multiple semiconductor chips are connected by a noble metal-coated silver wire for ball bonding, wherein the noble metal-coated silver wire for ball bonding comprises a noble metal coating layer on a core material made of pure silver or a silver alloy, the wire contains at least one sulfur group element, the noble metal coating layer comprises at least one palladium layer, the total palladium content relative to the entire wire is 0.01 mass % or more and 5.0 mass % or less, and the total sulfur group element content relative to the entire wire is 0.1 mass ppm or more and 100 mass ppm or less.
The present invention can provide a noble metal-coated silver bonding wire that suppresses corrosion at the bonding interface even under severe conditions of high temperature and high humidity in automobiles and the like and does not cause energization failure in a semiconductor device in which electrodes of a semiconductor chip and electrodes of lead frames or the like are connected by a bonding wire. Further, since the noble metal-coated silver bonding wire of the present invention can solve the problem of conventional copper bonding wires and coated copper bonding wires that their hard materials damage semiconductor chips, it is possible to provide noble metal-coated silver wires as alternatives not only to silver bonding wires and coated silver bonding wires but also to conventional copper bonding wires and coated copper bonding wires.
Embodiments of the present invention will be described. The embodiments shown below are intended to embody the technical idea of the present invention, and the present invention is not limited to the following examples.
The basic concept of the present invention is that a noble metal coating layer contains a sulfur group element that has a lower melting point than that of palladium and is highly reactive with silver, which forms the noble metal coating layer, and whereby a palladium distribution layer can stably remain on the FAB surface during ball bonding. That is, the presence of the palladium distribution layer at the bonding interface between FAB and the aluminum pad can suppress an increase in electric resistance, i.e., energization failure, caused by corrosion that occurs under the influence of water and halogen ions over a long period of time. The sulfur group elements are sulfur (S), selenium (Se), and tellurium (Te).
The melting points of the sulfur group elements are as follows: sulfur (S): 113° C., selenium (Se): 220° C., and tellurium (Te): 450° C., all of which are lower than the melting point of silver (962° C.). Further, the melting points of the sulfur group elements are lower than the melting points of palladium (1,552° C.) and gold (1,064° C.), which form the noble metal coating layer.
Although the mechanism of the characteristics of the present invention has not been completely clarified, it is presumed that the process of forming molten balls is characteristic. Therefore, the FAB formation process will be explained in the time sequence. First, when the bonding wire is heated, the sulfur group element in the noble metal coating layer with the lowest melting point becomes molten. Since the sulfur group element easily reacts with the silver of the core material, the molten sulfur group element is attracted to the silver. Next, the silver of the core material with the next lowest melting point melts and grows from small balls to large balls. At that time, at the interface between the silver of the core material and the palladium of the noble metal coating layer, the silver on the outermost surface of the core material reacts with the sulfur group element to form sulfurized silver (e.g., silver sulfide), which covers the periphery of the outermost surface of the silver of the core material. The sulfurized silver exerts a barrier effect between the silver of the core material and the palladium of the noble metal coating layer to suppress the palladium of the noble metal coating layer from melting into the silver of the core material even if the heating temperature increases to the melting point of palladium. Since the palladium of the noble metal coating layer is partially alloyed with the silver on the surface of the core material, palladium or a palladium-silver alloy, or both of them, are formed on the FAB surface to cover the FAB surface, although they are not completely separated. This layer is called a palladium distribution layer.
The palladium distribution layer on the FAB surface can be confirmed, for example, by performing area analysis of a surface obtained by cutting the FAB center from the wire neck toward the ball tip using an electron probe micro-analyzer (EPMA). Area analysis is a method of measuring the element distribution within a certain range of a sample and is an analysis method that allows for visual recognition of the distribution of each element.
The best requirement for solving the problems of the present invention is that the palladium distribution layer completely covers the FAB surface; however, the problems can be sufficiently solved when the palladium distribution layer covers the FAB surface to the extent that even a small amount of palladium is present at the bonding interface with the aluminum pad during bonding. That is, the presence of even a small amount of the palladium distribution layer at the bonding interface with the aluminum pad makes it possible to suppress an increase in electric resistance, i.e., energization failure, caused by corrosion at the bonding interface.
Moreover, in the noble metal-coated silver wire for ball bonding according to the present invention, because a gold layer is coated as the outermost layer of the noble metal coating layer (in particular, when a hard palladium layer is coated), the high malleability of gold makes it possible to prevent cracks and breaks on the wire surface during wire drawing. In addition, the wear on the diamond die is reduced, which can extend the life of the die and contribute to a reduction in processing costs. The coating with a gold layer as mentioned herein may be continuous in layers but may not necessarily be continuous in layers. This is because even if gold is scattered in an island form, there is a sufficient effect in improving wire drawability.
The definitions of the palladium layer and the gold layer in the noble metal coating layer of the present invention are reconfirmed. Each layer is computationally determined from the content of each element in the entire wire and is expressed as “layer” for convenience. In fact, when the content of the element is small, it may be scattered in islands rather than being continuous in layers; thus, the “layer” also includes a state of islands that do not form layers. This is because the problems of the present invention can be sufficiently solved even in the case of islands that do not form layers.
Furthermore, in the noble metal-coated silver bonding wire for ball bonding according to the present invention, it is preferable to use silver with a purity of 99.9 mass % or more as the core material because the electric resistivity of the wire can be reduced. However, since there is a large difference in material strength, malleability, and elongation between silver and the noble metal coating layer, it may cause the noble metal coating layer to peel off from the silver of the core material during wire drawing or cause a wire breakage or the like. Therefore, it has been found that in order to perform wire drawing smoothly, when a small amount of copper is mixed with the silver of the core material to increase the strength of the core material, the difference in material strength and elongation between the noble metal coating layer and the core material is reduced, and the workability during wire drawing is improved. The same effect can be obtained by adding gold, platinum, palladium, or the like to the core material.
In the noble metal-coated silver bonding wire for ball bonding according to the present invention, the palladium content relative to the entire wire is set to 0.01 mass % or more and 5.0 mass % or less for the following reasons. That is, the reason why the lower limit of the palladium content is set to 0.01 mass % or more is that if the palladium content is less than 0.01 mass %, the FAB surface cannot be covered with a palladium distribution layer, and corrosion cannot be suppressed at the bonding interface between FAB and the aluminum pad. Further, the reason why the upper limit of the palladium content is set to 5.0 mass % or less is that the circularity of FAB cannot be stabilized if the palladium content exceeds 5.0 mass %.
In the noble metal-coated silver bonding wire for ball bonding according to the present invention, the reason why the noble metal coating layer contains a sulfur group element is that it has been found that the FAB surface can be covered with a palladium distribution layer when at least one sulfur group element selected from sulfur (S), selenium (Se), and tellurium (Te) is present in an appropriate amount depending on the component composition of the noble metal coating layer. Although the problems of the present invention can be solved by incorporating a sulfur group element into the noble metal coating layer, the noble metal coating layer is a very thin layer, and when the content of the sulfur group element is small, it may become an island shape rather than a layer shape; thus, it is difficult to analyze whether the noble metal coating layer contains a sulfur group element, and it is also very difficult to analyze the sulfur group element content of the noble metal coating layer. Therefore, the claims specify the sulfur group element content relative to the entire wire.
The reason why the lower limit of the sulfur group element content is set to 0.1 mass ppm or more is that the palladium distribution layer cannot remain on the FAB surface if the sulfur group element content is less than 0.1 mass ppm. Further, the reason why the upper limit of the sulfur group element content is set to 100 mass ppm or less is that the circularity of the ball cannot be stabilized during ball bonding if the sulfur group element content exceeds 100 mass ppm.
In the noble metal-coated silver bonding wire for ball bonding according to the present invention, it is preferable that the noble metal coating layer further comprises at least one gold layer. In particular, it is preferable that a gold layer is formed on the outer peripheral surface of the palladium layer. This is because when continuous wire drawing is performed while a gold layer is provided on the palladium layer, the wear on the wire drawing die can be reduced. Further, it is preferable that a gold layer is formed on the core material surface of the palladium layer. This is because the intermediate gold layer serves as a cushion to mitigate the difference in elongation between the core material and the palladium layer during continuous wire drawing and reduces wire drawing defects in the noble metal coating layer.
The reason why the lower limit of the gold content relative to the entire wire is set to 0.01 mass % or more is that wire drawing defects cannot be suppressed if the gold content is less than 0.01 mass %. Moreover, the reason why the upper limit of the gold content relative to the entire wire is less than 1.0 mass % is that there is no change in the suppression of wire drawing defects even if the gold content exceeds 1.0 mass %. Since gold is sufficiently effective even in a small amount and is expensive, it is preferable to reduce the amount thereof as much as possible.
The silver alloy of the core material preferably contains 0.005 mass % or more and 2.0 mass % or less of copper. The reason why the lower limit of the copper content relative to the entire wire is set to 0.005 mass % or more is that wire drawing defects cannot be suppressed if the copper content is less than 0.005 mass %. Further, the reason why the upper limit of the copper content relative to the entire wire is set to less than 2.0 mass % is that if the copper content exceeds 2.0 mass %, the electric resistivity increases and the wire strength also increases, making wire drawing difficult. The same effect can be obtained when the silver alloy of the core material contains at least one of gold, platinum, or palladium in a total amount of 0.005 mass % or more and 2.0 mass % or less.
The content of each element in the noble metal-coated silver bonding wire for ball bonding according to the present invention is measured by inductively coupled plasma atomic emission spectroscopy (ICP-AES), inductively coupled plasma mass spectrometry (ICP-MS), glow discharge mass spectrometry (GDMS), time-of-flight secondary ion mass spectrometry (TOF-SIMS), or the like.
Regarding the structure of the noble metal coating layer laminated on the core material in the noble metal-coated silver bonding wire for ball bonding according to the present invention, the order of lamination can be confirmed by AES analysis in the depth direction from the surface layer of the bonding wire to the core material. In addition, the lamination and arrangement of each element can also be confirmed by obtaining a cross section of the bonding wire by mechanical polishing or using a focused ion beam system (FIB) and performing line analysis of elements in the surface portion or point analysis of multiple points using EDX attached to a scanning electron microscope (SEM), EPMA, or EDX attached to TEM.
In the present invention, the noble metal element in the noble metal coating layer, the palladium element in the intermediate palladium layer, and the gold element in the gold skin layer and the intermediate gold layer may be alloyed in each layer without a portion of 100 mass % of each element. They are defined as the noble metal coating layer, the intermediate palladium layer, the gold skin layer, and the intermediate gold layer, including the above cases.
(Production Method)
Next, the method for producing a noble metal-coated silver bonding wire for ball bonding according to the present invention will be described. The method for producing a noble metal-coated silver bonding wire for ball bonding according to the embodiment is not particularly limited to the following.
(Core Material)
The pure silver or silver alloy used in the core material of the bonding wire can be produced by melting raw materials simultaneously. An arc heating furnace, a high-frequency heating furnace, a resistance heating furnace, or the like can be used for melting. It is preferable to use a continuous casting furnace. The procedure is as follows. Pre-weighed raw materials are placed in a carbon crucible, heated and melted in a vacuum or an inert atmosphere such as nitrogen gas or argon gas, and then cooled. The obtained pure silver or silver alloy ingot is formed into a thin wire with a final wire diameter by repeating rolling, drawing using a die, and continuous wire drawing.
(Noble Metal Coating Layer)
The method for forming a noble metal coating layer is a method in which a noble metal coating layer is formed on a silver wire with a final wire diameter, or a method in which a noble metal coating layer is formed on a silver wire after continuous casting or a silver wire with an intermediate wire diameter, followed by repeated continuous drawing to process the wire to a final wire diameter.
The method for forming a noble metal coating layer on the surface of a silver wire, which is the core material, may be a wet plating method, a dry plating method, a melting method, or the like. As the wet plating method, an electrolytic plating method, an electroless plating method, or the like can be used for production. It is also possible to combine an electrolytic plating method called strike plating or flash plating. The solution used for electroless plating may be substitution type, reduction type, or self-decomposition type. To form a thick noble metal coating layer, self-decomposition plating can be used in combination after substitution plating. As the dry plating method, physical adsorption such as sputtering, ion plating, and vacuum deposition, and chemical adsorption such as plasma chemical vapor deposition (CVD), can be used. Since all of these methods are dry plating, there is no need for cleaning after forming a noble metal coating layer as there is in wet plating, and there is no concern about surface contamination during cleaning.
The method for forming the silver wire described above will be described in detail. A cylindrical silver alloy with a diameter of 3 mm or more and 10 mm or less obtained by melt casting is drawn to a diameter of 1.2 mm or more and 2.0 mm or less. Then, wire drawing is continuously performed using a die to produce a wire with a diameter of 300 μm or more and 600 μm or less. These steps can also be performed by continuous casting.
The method for forming a noble metal coating layer on the silver wire will be described in detail. The noble metal coating layer can be formed by wet plating. Preparation is performed by adding a sulfur (S) compound, a selenium (Se) compound, or a tellurium (Te) compound as a crystal modifier to a palladium electroplating bath for a palladium layer. Further, a gold electroplating bath is used when a gold layer is provided. Then, wire drawing is repeated to draw the wire to a final wire diameter of 12 μm or more and 60 μm or less, preferably 15 μm or more and 35 μm or less, and a final heat treatment is performed.
It is effective to perform the final heat treatment while continuously drawing the noble metal-coated silver wire with the final wire diameter because high productivity can be obtained. Specifically, the noble metal-coated silver wire with the final wire diameter is continuously passed through an electric furnace set to an appropriate temperature, or the noble metal-coated silver wire with the final wire diameter wound on a spool or the like is left in an oven set to an appropriate temperature for a certain period of time.
When ball bonding is performed using a noble metal-coated silver bonding wire for ball bonding produced by the production method according to the embodiment of the present invention, a palladium distribution layer is formed on the FAB surface, thereby exhibiting an excellent characteristic that it can suppress energization failure caused by the corrosion of intermetallic compounds formed between the aluminum pad and the bonding wire. Further, the use of the noble metal-coated silver bonding wire for ball bonding according to the present invention makes it possible to realize a semiconductor device with a longer life than conventional semiconductor devices.
Typical examples of a semiconductor device according to an embodiment of the present invention and a method for producing the same will be described with reference to
A semiconductor chip 2 and lead frames 3 are bonded by a noble metal-coated silver bonding wire 4, followed by sealing with a ceramic or mold resin to protect the noble metal-coated silver bonding wire 4 and the bonding portions. Then, external leads are molded into a predetermined shape. Finally, product inspection such as electrical characteristic inspection and visual inspection, and reliability inspection such as an environmental test and a life test are performed, after which a semiconductor device 1 is obtained.
Next, the internal structure of a semiconductor device according to another embodiment of the present invention will be described with reference to
Multiple semiconductor chips 2 are arranged on a substrate 5, and electrodes 6 of the substrate 5 and electrodes (not shown) of the semiconductor chips 2, and electrodes (not shown) of the semiconductor chips 2 and electrodes (not shown) of the semiconductor chips 2 are electrically bonded by a noble metal-coated silver wire 4. The electrodes of the semiconductor chips 2 electrically bonded by the noble metal-coated silver wire 4 also include bumps (not shown) previously bonded to the electrodes on the semiconductor chips 2. Specifically, semiconductor devices refer to logic ICs, analog ICs, discrete semiconductors, memories, optical semiconductors, and the like.
The present invention will be further described below while showing Examples and Comparative Examples; however, the present invention is not limited to the following Examples as long as the gist thereof is not exceeded.
First, the Examples will be described. Silver with a purity of 99.9 mass % or more was used for a core material, and gold and palladium were used for a noble metal coating layer. In the method used herein, a noble metal coating layer was laminated on a silver wire with an intermediate wire diameter, followed by continuous drawing to process the wire to a final wire diameter. The method for forming the noble metal coating layer on the surface of the core material was an electroplating method in which the wire was continuously fed and immersed in a plating bath. Then, the bonding wire processed to the final wire diameter was subjected to a final heat treatment. In this manner, bonding wires of Examples 1 to 20 were produced.
Next, FAB was formed on the produced bonding wires using a commercially available bonding device (K&S ICONN) while blowing nitrogen gas. First bonding was performed on an aluminum alloy pad on a Si chip for evaluation heated to 200° C. by an ultrasonic thermocompression ball bonding method. Second bonding was performed between silver-plated leads on lead frames (200 pins) made of 42 alloy by an ultrasonic thermocompression stitch-bonding method, thereby connecting 200 wires in total. Then, the shape of the pressure-bonded balls was observed.
(Evaluation of Circularity)
The circularity of the pressure-bonded balls is evaluated by the ratio of Y/X, where Y is the vertical diameter (in the direction of applying ultrasonic waves) of the pressure-bonded ball in the bonding wire bonding device, and X is the horizontal diameter (in the direction orthogonal to the ultrasonic wave-applying direction). The evaluation criteria were as follows: “∘” (passed) if 0.8 to 1.2, and “X” (failed) if 0.79 or less or 1.21 or more. However, even if the circularity was “∘” (passed), the evaluation of circularity was “X” (failed) for wires with a core dislocation phenomenon. The core dislocation phenomenon is a phenomenon in which the pressure-bonded ball is formed asymmetrically with respect to the wire axis. If there is large core dislocation, the ball comes into contact with the adjacent ball to cause a short circuit failure. In addition, core dislocation may also cause insufficient bonding strength. The circularity evaluation for the pressure-bonded ball shape of the bonded wires of the Examples was “∘” (passed), as shown in Table 1. Table 1 shows the evaluation results of noble metal-coated silver wires.
Thereafter, the ball bonding wire bonded to the aluminum alloy pad was sealed with a commercially available epoxy resin, and electric resistance was measured. The electric resistance was measured using a “Source Meter (model 2004)” produced by KEITHLEY, a dedicated IC socket, and a specifically constructed automatic measurement system, using the DC four-terminal method in which a constant current was supplied from probes to adjacent external leads (pairs in which the pad on the semiconductor chip was short-circuited were selected), and the voltage between the probes was measured.
(HAST Reliability Evaluation)
Next, a highly-accelerated temperature and humidity stress test (HAST) was performed. The HAST reliability evaluation was performed in such a manner that the wire produced above was placed in a HAST device and left for 192 hours in an atmosphere of a temperature of 130° C., a relative humidity of 85%, and 2 atm. Thereafter, the electric resistance was measured and evaluated by the rate of increase of electric resistance before the test. The reason for selecting this evaluation method is that, depending on the progress of the formation of a corrosion layer at the bonding interface caused by the corrosion of intermetallic compounds between silver and aluminum formed at the aluminum bonding interface of the wire, the bonding area is reduced, the electrical conductivity decreases, and the electric resistance increases. Therefore, measuring the rate of increase of electric resistance of the wire before and after HAST is suitable as an evaluation method for solving the problems.
Table 1 shows the results. Wires with an average rate of increase of electric resistance of 20% or less between 100 pairs of adjacent external leads before and after HAST were evaluated as “∘” (passed), and wires with an average rate of increase of electric resistance exceeding 20% were evaluated as “X” (failed). In all of the wires of the Examples, the average rate of increase of electric resistance after HAST was 20% or less, compared with that before HAST.
Thereafter, when the cross section of the bonding interface between the aluminum alloy pad on the evaluation chip and the wire was analyzed by EDX attached to SEM, palladium was detected at the bonding interface. The detected palladium is derived from the palladium distribution layer formed on the FAB surface shown in
Noble metal-coated silver wires of Comparative Examples were produced in the same manner as in the Examples. When FAB was formed on the bonding wires of the Comparative Examples while blowing nitrogen gas as in the Examples, distorted eccentric balls were formed in Comparative Examples 23, 24, 26, and 27, and the evaluation of circularity was “X” (failed). These results reveal that the circularity is attributable to the palladium content (mass %) and the sulfur group element content (mass %). The bonding wires that were evaluated as “X” (failed) in the circularity evaluation were not evaluated for HAST reliability, and they were thus expressed as “-” (not performed) in Table 1.
Comparative Examples 21, 22, 25, and 28 passed the evaluation of circularity; however, the rate of increase of electric resistance after HAST exceeded 20% as compared with that before HAST, and they were thus evaluated as “X” (failed). When the cross section of the bonding interface between the aluminum alloy pad on the evaluation chip and the bonding wire was analyzed by EDX attached to SEM, palladium was not detected at the bonding interface. These results reveal that the detection of palladium at the bonding interface, i.e., coating of the FAB surface with a palladium distribution layer, depends on the palladium content (mass %) and the amount of sulfur group element added. It is also revealed that the presence of palladium at the bonding interface is the key to solving the problems of the present invention.
TABLE 1
Sulfur group
element
HAST
Pd
(mass ppm)
Circularity
reliability
Final
(mass %)
S
Se
Te
evaluation
evaluation
evaluation
Example
1
1.4
6
—
—
∘
∘
∘
2
0.5
—
4
—
∘
∘
∘
3
0.2
—
—
5.5
∘
∘
∘
4
0.7
3
—
—
∘
∘
∘
5
0.05
—
0.5
—
∘
∘
∘
6
1.3
—
—
30
∘
∘
∘
7
1.7
10
10
—
∘
∘
∘
8
2.8
—
11
24
∘
∘
∘
9
1.0
6
8
—
∘
∘
∘
10
3.5
10
—
18
∘
∘
∘
11
2.9
4
7
22
∘
∘
∘
12
0.02
—
—
0.5
∘
∘
∘
13
2.0
—
19
—
∘
∘
∘
14
4.8
—
—
62
∘
∘
∘
15
2.6
4
6
20
∘
∘
∘
16
0.5
3
—
—
∘
∘
∘
17
1.0
—
9
—
∘
∘
∘
18
1.5
—
—
35
∘
∘
∘
19
2.1
7
12
—
∘
∘
∘
20
2.5
—
7
20
∘
∘
∘
Comparative
21
0.005
—
—
—
∘
x
x
Example
22
0.8
—
—
—
∘
x
x
23
5.5
—
—
—
x
—
x
24
6.0
24
—
—
x
—
x
25
1.4
0.01
—
—
∘
x
x
26
2.8
—
86
37
x
—
x
27
5.2
—
—
120
x
—
x
28
0.008
—
—
0.2
∘
x
x
The results of the Examples and Comparative Examples above demonstrate that the presence of palladium at the bonding interface between the aluminum alloy pad on the evaluation chip and the bonding wire has a great influence on the electrical conductivity of the bonding wire, i.e., bonding life. The palladium at the bonding interface is derived from the palladium distribution layer formed on the FAB surface shown in
As described above, because the palladium distribution layer stably remains on the FAB surface, it is possible to provide a noble metal-coated silver bonding wire that can suppress an increase in electric resistance, i.e., energization failure, caused by corrosion occurring at the bonding interface, even under severe conditions of high temperature and high humidity in automobiles and the like.
In addition, the noble metal-coated silver wire for ball bonding according to the present invention can exhibit an excellent characteristic that it can suppress energization failure caused by the corrosion of intermetallic compounds formed between the aluminum pad and the bonding wire. Therefore, the use of the noble metal-coated silver bonding wire for ball bonding of the present invention in a semiconductor device makes it possible to provide a semiconductor device having a longer life than conventional semiconductor devices.
The noble metal-coated silver wire for ball bonding according to the present invention suppresses an increase in electric resistance even under high-temperature and high-humidity conditions and has uses in various applications such as logic ICs, analog ICs, discrete semiconductors, and memories, as well as optical semiconductors.
Antoku, Yuki, Chiba, Jun, Kawano, Shota
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